Double layer fabric with puckered upper layer and method of making same



June 12, 1956 G. G. SLOUGH 2,749,947 DOUBLE LAYER FABRIC WITH PUCKERED UPPER LAYER AND METHOD OF MAKING SAME Filed Oct. 21. 1952 2 Sheets-Sheet 1 FIG. I

INVENTOR.

650265 6. SLOUGH G. SLOUGH DOUBLE LAYER FABRIC WITH PUCKERED UPPER LAYER AND METHOD OF MAKING SAME Filed OGt. 21, 1952 June 12, 1956- 2 Sheets-Sheet 2 INVENTOR. GEORGE G. SLOUGH A TTO ENE 75 United States Patent DOUBLE LAYER FABRIC WITH PUCKERED UPPER.

LAYER AND METHOD OF MAKING SAME George G. Slough, Bethlehem, Pa., assignor to Kanmak Textiles, Inc., New York, N. Y., a corporation of New York Application October 21, 1952, Serial No. 315,968

25 Claims. (Cl. 139423) This invention relates to improvements in puckered fabrics.

In one embodiment of my invention, I provide a fabric comprising an upper layer of cloth and a lower layer of cloth. Either the lower warp threads or the lower filler threads, or both, are elastic and are held in stretched condition during the weaving of the cloth. The upper layer of cloth and the lower layer of cloth are joined together at selected points. As an example, and without limitation thereof, certain of the upper warp threads may be interwoven at selected points along their length with lower filler threads.

It will be apparent from the above that when the elastic threads return to their normal unstretched condition, upon the completion of the Weaving of the fabric the upper layer of cloth is puckered in the intervals bounded by the points or areas at which it is joined to the lower layer of cloth. It is possible to produce a variety of designs in the upper layer of cloth by varying the manner in which it is interwoven with the lower layer of cloth, thereby varying the manner in which the upper layer is puckered.

An important advantage of this invention is that novel ornamental puckered patterns may be produced in the fabric, with the elastic threads being substantially concealed from view when the fabric is viewed fromabove.

Other objects and advantages of the invention will become apparent from the following description, in conjunction with the annexed drawings, in which certain preferred embodiments are disclosed. However, the embodiments shown are only illustrative of the large variety of designs which may be made in accordance with this invention.

A first embodiment of the invention isshown in Figs. 1-3. In this embodiment, the lower filler or lateral threads are elastic, and certain of the warp threads of the upper layer of cloth are interwoven with the lower layer of cloth at longitudinally spaced points, the corresponding interwoven points of said warp threads being laterally alined. When the elastic threads contract, the upper layer of cloth puekers between the interwoven intervals to form longitudinally spaced, laterally extending ridged or puckered areas. I

Fig, 1 is a plan view of a fabric made in accordance with the first embodiment.

Fig. 2 is a section on line 22 of Fig. 1, the scale being greatly enlarged.

'Fig. 3 is a section on line 33 of Fig. 1, the scale being greatly enlarged.

Fig. 4 is a view similar to Fig. 2, showing a second embodiment of the invention in which the warp threads of the lower layer of cloth are elastic.

Fig. 5 is a view similar to Fig. 2, showing a third embodiment of the invention in which both the warp threads and the filler threads of the lower layer of cloth are elastic.

Fig. 6 is a view similar to Fig. 3, also showing the fourth embodiment of the invention.

2,749,947 Patented June 12, 1956 ice First embodiment In this embodiment, I provide a fabric which has a lower layer of cloth comprising lower longitudinal warp threads 20 and lower lateral filler threads 21. The threads 20 and 21 maybe interwoven in any suitable selected regular pattern. In the pattern illustrated, warp thread 20a passes over a filler thread 21a and under a successive filler thread 21b; and a successive warp thread 2% passes under said filler thread 21a and over said filler thread 21b. The fabric of this embodiment also has an upper layer of cloth comprising upper longitudinal warp threads 22 and upper lateral filler threads 23. These warp threads 22 and filler threads 23 may be interwoven with each other in any suitable selected regular pattern. In the pattern illustrated, warp thread 22a passes over a filler thread 23a and under a successive filler thread 23]); and a successive warp thread 22b passes under said filler thread 22a and over said filler thread 22b.

The upper layer of cloth floats above the lower layer of cloth, except that certain of the upper warp threads 22 are interwoven at periodic intervals along their lengths with the lower filler threads 21. In the pattern illustrated, I select for such interweaving laterally spaced sets of three successive threads 22b for such interweaving. This is clearly shown in Fig. 7. As is clearly shown in Fig. 6, at periodic intervals along its length, each said selected thread 22b, instead of being passed directly under an upper filler thread 23a, is dropped so that it is passed under a lower filler thread 21b. Optionally, the corresponding intervals at which the respective selected threads 22b are,

interwoven with the lower filler threads 21b are laterally alined, as is shown in Fig. 5. These intervals give the effect of small openings 24 in the upper layer of cloth.

As, a result of the above-described construction the fabric is divided into a plurality of longitudinally extending, laterally spaced zones or bands 25 in which the upper layer of cloth is unconnected to the lower layer of cloth. Between the bands 25, the upper layer is connected to the lower layer at the points 24, which are sufficiently close together laterally to minimize puckering of the upper layer between the bands 25.

In this embodiment, the lower filler threads 21 are preferably elastic threads of any suitable type, such elastic threads being well known in the art. For example, the threads 21 may be made of rubber covered with fabric. While the fabric is being woven, tension is exerted along the axis of each thread 21 so as to maintain said thread in a stretched condition. For example, each thread 21 may be stretched to a length a third or more greater than its normal length. During weaving, the upper layer of cloth is substantially smooth.

After the fabric is woven, the tension on threads 21 is relaxed, and they resume their normal length. As a result, the bands 25 are laterally contracted.

Preferably, said bands 25 are sufficiently narrow so that only one upward pucker is formed in each band 25. As a result, a plurality of longitudinal ridges are formed in the upper layer of cloth, each said ridge being formed in a band 25 and extending the full length of the fabric. This is clearly shown in Fig. 5. Intermediate the bands 25, the excess of the upper layerof cloth tends to move Second embodiment In this embodiment, the warp threads of the lower layer of cloth are elastic.

Fig. 4 corresponds to Fig. 2, except that in this embodiment, the inelastic lower warp threads 20 of Fig. 6 are replaced by elastic warp threads 30, and the elastic lower filler threads 21 of Fig. 6 are replaced by inelastic filler threads 31.

It will be apparent that in this embodiment, it is possible to obtain a fabric in which there are longitudinally spaced, laterally extending zones or bands, each said band being puckered to form a lateral ridge therein.

Third embodiment In this embodiment, the warp threads and the filler threads of the lower layer of cloth are elastic.

The upper layer of cloth of Figs. 5 and 6 is' substantially the same as in Fig. 2. The lower layer of cloth is the same as in Fig. 2, except that the inelastic lower warp threads 20 of Fig. 2 are replaced by elastic warp threads 40.

In this embodiment, unlike the embodiment of Figs. 1-3, I prefer not to interweave successive upper warp threads 2217 with the'lower filler threads 2" Instead, as may be seen by contrasting Fig. 6 with Fig. 3, I prefer to interweave spaced individual threads 22b with the lower filler threads. Otherwise, the fabric of this embodiment is woven in substantially the same manner as in the embodiment of Figs. 1-3;

As will be seen from Figs. 5 and 6, the contraction of the elastic threads 21 and 40, upon completion of the weaving, divides the fabric into rectangular areas in which the upper layer of cloth is puckered both longitudinally and laterally.

It will be apparent that I have invented a fabric which comprises an upper layer of cloth and a lower woven layer of cloth comprising a set of warp threads and a set of weft threads, at least one of said sets of thread being all elastic and being maintained in stretched condition during the forming of the fabric. During the forming of the fabric, the two layers of cloth are joined at selected points which are spaced in: the direction of length of said elastic threads, whereby to produce a puckering of' the upper layer of cloth upon permitting the elastic threads to resume their normal length.

I have disclosed a number of specific embodiments of my'invention, in each of which the upper layer of clothalso comprises a set of warp threads interwoven with a set of weft threads. It will be apparent that my invention includes a fabric in which selected remaining threads of either of said layers extending in either of said directions are respectively interwovenat selected points thereon withrespective threads of the other layer extending inthe other direction.

The disclosed embodiments all show a fabric inwhich said selected remaining threads are selected from one set of threads of the upper layer. However, the invention is clearly not limited to such a construction.

thelower warp threads, the lower filler" threads, or: both, may be elastic. The manner in which the selected upper set of threads is interwoven with the lower" layer of cloth determines the type of pattern. which will be produced upon contraction of the elastic threads.

It, will be apparent that while I have disclosed preferred' embodiments of my invention and have indicated various changes, additions and omissions which may be made. therein, numerous other embodiments of my invention, as well as-other changes, additionsand omissions, may be madewithout departing from-the scope and. spirit of the invention.

I claim:

1.. A textile fabric comprising an. upper layer of cloth, said. upper layer of cloth comprising an: upper set' of warpthreads interwoven with an upper set of weftthreads, and a lower layer of cloth, said lower layer of cloth comprising a lower set: of warp threads interwoven with a lower set of weft threads, said lower weft. threads. being all elastic and being respectively adapted to be stretchedfrom a condition of normal length to a stretched condition and to be maintained in said stretched condition while the fabric is being formed, certain selected remaining threads of either of said layers extending in either direction being respectively interwoven at selected points thereon with respective threads of the other layer extending in the other direction, said points being dispersed over the area of said upper layer whereby to produce a puckering of said upper layer upon permitting said stretched threads to return to their condition of normal length.

2. A fabric in accordance with claim 1, in which said selected remaining threads are selected only from among the upper warp threads.

3. A fabric in accordance with claim 2, in which said selected upper warp threads are respectively alternately separate from the lower layer intermediate successive selected lower weft threads with which said selected upper longitudinal threads are interwoven and interwoven with the lower weft threads intermediate successive selected lower weft threads, said upper weft threads being interwoven with said selected upper warp threads only where same are separate from said lower layer.

4. A fabric in. accordance with claim 1, in. which said selected remaining threads comprise sub-sets of the upper warp threads, each said subset comprising a plurality of successive upper warp threads, said sub-sets being separated by unselected upper warp threads, saidselected threads being each interwoven with the same spaced lower weft threads, said fabric having longitudinal ridges therein extending in the direction of the warp between said sub-sets of threads.

5. A fabric in accordance with claim 4, in. which said upper weft threads are interwoven with said upper warp threads only and along the entire length of said upper longitudinal threads.

6. A fabric in accordance with claim 1, in which said selected remaining threads comprise sub-sets of the upper warp threads, each said sub-set comprising a plurality of successive upper warp threads, said sub-sets being separated by unselected upper warp threads, said selected threads being. each interwoven with respective selected spaced lower weft threads, said fabric having longitudinal ridges therein extending in. the direction of the warp between s'aid' sub-sets of threads.

7. A fabric in accordance with claim 6, in which said upper weft threads are interwoven with said upper warp threads. only and along the entire length of said upper warp threads.

8. A fabric in accordance with claim 7, in which said upper weft threads are interwoven with said upper longitudinal threads only and along the entire length of said upper warp threads.

9. A fabric in accordance with claim 6, said lower warp threads being extended over said lower weft threads atthc respective points thereon at which said selected up per warp threads are interwoventherewith and being elsewhere. floated under said lower weft threads.

10;. A fabric: in accordance withclaim 8, said: lower warp threads being extended over said lower. weft threads at the respective points thereon at which said; selected upper warp threads are interwoven therewith and being; elsewhere floated under. said lower: weft threads.

11. A fabric in accordance with claim 1,. in which said lower warp threads are also elastic and are maintained in stretched condition while the fabric is. being formed.

12.. A. fabric in accordance with claim 11, in, which said. selected remaining threads, comprise sub-sets of the upper warp threads, each said. sub-set comprising a plurality of. successive upper, warp threads, said sub-sets being, separated by unselected upper warp threads, said: selected. threads. being each. interwoven with. respective selected spaced. lower warp threads.

13. A fabric in accordance claim 12, in which said selected warp threads are each interwoven with the same lower weft threads.

14. A method of producing a puckered pattern in a textile fabric, comprising interweaving an upper set of warp threads and an upper set of weft threads to form an upper layer of cloth, simultaneously interweaving a lower set of warp threads and a lower set of weft threads to form a lower layer of cloth which is in transverse registration with said upper layer of cloth, said lower weft threads being all elastic, maintaining said elastic threads in stretched condition throughout the forming of said layers, and during the forming of said layers interweaving certain selected threads of either of said layers extending in either direction at selected points thereon with respective threads of the other layer extending in the other direction, said points being dispersed over the area of said upper layer whereby to produce said puckered pattern upon permitting said stretched threads to return to their normal length.

15. A method of producing a puckered pattern in a textile fabric, comprising interweaving an upper set of warp threads and an upper set of weft threads to form an upper layer of cloth, simultaneously interweaving a lower set of warp threads and a lower set of weft threads to form a lower layer of cloth which is in transverse registration with said upper layer of cloth, said lower weft threads being all elastic, maintaining said elastic threads in stretched condition throughout the forming of said layers, and during the forming of said layers interweaving selected upper warp threads with selected spaced lower weft threads, whereby to produce said puckered pattern upon permitting said stretched threads to return to their normal length.

16. A textile fabric comprising an upper layer of cloth, said upper layer of cloth comprising an upper set of warp threads interwoven with an upper set of weft threads, and a lower layer of cloth, said lower layer of cloth comprising a lower set of warp threads interwoven with a lower set of weft threads, a lower set of threads being all elastic and being respectively adapted to be stretched from a condition of normal length to a stretched condition and to be maintained in said stretched condition while the fabric is being formed, certain selected upper warp threads being respectively interwoven at selected points thereon with respective threads of the other layer extending in the other direction, said points being dispersed over the area of said upper layer whereby to produce a puckering of said upper layer upon permitting said stretched threads to return to their condition of normal length.

17. A fabric in accordance with claim 16, in which said selected upper warp threads are respectively alternately separate from the lower layer intermediate successive selected lower weft threads with which said selected upper warp threads are interwoven and interwoven with the lower weft threads intermediate successive selected lower weft threads, said upper weft threads being interwoven with said selected upper warp threads only where same are separate from said lower layer.

18. A fabric in accordance with claim 16, in which said selected upper warp threads comprise sub-sets of said upper warp threads, each said sub-set comprising a plurality of successive upper warp threads, said sub-sets being separated by unselected upper warp threads, said selected upper warp threads being each interwoven with the same spaced lower weft threads, said fabric having ridges therein extending in the direction of the warp between said sub-sets of threads.

19. A fabric in accordance with claim 18, in which said upper weft threads are interwoven with said upper warp threads only and along the entire length of said upper warp threads.

20. A fabric in accordance with claim 16, in which said selected upper warp threads comprise sub-sets of said upper warp threads, each said sub-set comprising a plurality of successive upper warp threads, said sub-sets being separated by unselected upper warp threads, said selected upper warp threads being each interwoven with respective selected spaced lower weft threads, said fabric having ridges therein extending in the direction of the warp between said sub-sets of threads.

21. A fabric in accordance with claim 20, in which said upper weft threads are interwoven with said upper warp threads only and along the entire length of said upper warp threads.

22. A fabric in accordance with claim 20, said lower warp threads being extended over said lower weft threads at the respective points thereon at which said selected upper warp threads are interwoven therewith and being elsewhere floated under said lower weft threads.

23. A fabric in accordance with claim 21, said lower warp threads being extended over said lower weft threads at the respective points thereon at which said selected upper warp threads are interwoven therewith and being elsewhere floated under said lower weft threads.

24. A fabric in accordance with claim 16, in which said lower weft threads are the lower set of threads which is all elastic.

25. A fabric in accordance with claim 16, in which said upper weft threads are interwoven with said upper warp threads only and along the entire length of said upper warp threads.

References Cited in the file of this patent UNITED STATES PATENTS 1,792,453 Thomas Feb. 10, 1931 1,922,943 Gobeille Aug. 15, 1933 2,129,344 Clement Sept. 6, 1938 2,184,751 Nathanson Dec. 26, 1939 2,190,053 Amyot Feb. 13, 1940 2,231,388 Kahil Feb. 11, 1941 2,254,339 Wylde Sept. 2, 1941 2,424,928 Glendinning July 29, 1947 2,597,580 Gluck May 20, 1952 FOREIGN PATENTS 268,166 Great Britain Mar. 31, 1927 

